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SERVICE MANUAL

Introduction This manual details the steps necessary to replace many components on the LX810. It is not intended to be a comprehensive manual for replacing all parts on the LX810. Instead it is broken down into modules or assemblies. The manual explains how to replace the entire assembly, not specific parts on each assembly. The assemblies included in the manual are the ones most likely to be damaged or need replacement after extensive use. You will need only a few tools to complete these repairs. A T10 Torx screwdriver, a Phillips #1 screwdriver and a straight screwdriver are required. Long shank screwdrivers work best. For ease of use, the screwdrivers should be magnetized. Section Page 1. Removing the Top Cover ……………………………………………………………………………………… 2 2. Replacing the Printer Module ……………………………………………………………………………….... 4 3. Removing the Front Cover……………………………………………………………………………………... 12 4. Replacing the Label Clamp Assembly………………………………………………………………………… 14 5. Replacing the Ink Pads…………………………………………………………………………………………. 18

A. Replacing the Center Air Filter………………………………………………………………………... 18 B. Replacing the left and right side Ink Pads…………………………………………………………… 19 6. Replacing the Feed Motor……………………………………………………………………………………… 21 7. Replacing the Main Board……………………………………………………………………………………… 23 8. Replacing the Loop Sensor…………………………………………………………………………………….. 25 9. Removing a Jam in the Label Sensor……………………………………………………………………….. 26 Appendix A – Parts List………………………………………………………………………………………….. 27

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Section 1: Removing the Top Cover 1. Open the Top Cover. 2. Remove two Phillips Head screws as shown.

3. Close the Top Cover. 4. Remove two Phillips Head screws as shown.

5. Pull the Top Cover back until you see a gap as shown.

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6. Open the Top Cover. 7. Grab the cover by the bottom and tilt it upward. 8. Pull the cover from the base.

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Section 2: Replacing the Print Module • Part Number 660200

1. Remove the Top Cover. Refer to Section 1 for instructions. 2. Remove two T10 Torx screws as shown.

3. Remove the USB Cable from the Main Board.

4. Remove three Phillips screws as shown. 5. Remove the USB Connection. 6. Remove the metal Board Cover. (Steps 4-6 are not necessary for units with Serial Numbers greater than 2050300000. It is necessary to remove this cover on earlier models because it allows access to a screw that is not present on later models)

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7. Remove two screws from the Star Wheel Plate Assembly. 8. Remove the Assembly.

9. Remove three T10 torx screws from Upper Clamp Plate. 10. Remove Upper Clamp Plate.

11. Remove Exit Shaft.

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12. Use a flat screwdriver to gently pry the shaft up enough to grab it with your finger (Step 12).

13. Grab the shaft with your left hand. 14. Press down on the far right side of the shaft with your right hand and pull up and to the left in the middleuntil the shaft is free from its mounting holes.

15. Unhook the shaft from the belt on the left side.

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16. Disconnect the connections J14 (Lex Power) and J5 (Lex Ctrl) from the main board.

17. Remove J14 and J5 wires from the wire harness.

18. Remove the motor wires from the wire harness.

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19. Move the print carriage to the middle of the print area to access the print module screws.

20. Remove right Print Module mount screw.

21. Loosen this screw. (This step is not necessary for units with Serial Numbers greater than 2050300000)

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22. Remove two left side mount screws. 23. Slide the module forward slightly and tip the front portion up in order to remove it from the printer.

The parts shown to the right were removed and should be reinstalled in reverse order. Note: Print Module is shown with metal Board Cover removed. The new Print Module will have the Board Cover attached. It will be necessary to remove this cover in order to install the new module for units with serial numbers less than 2050300000.

When replacing the print module take note of the screw and notched pins and the corresponding screw notch and tabs on both sides of the print module. The tabs should be placed into the notched pins on both sides of the Print Module. Screw. Right Side Notched Pin.

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Screw Notch. Right Side Tab.

Left Side Notched Pin.

Right Side Tab.

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When replacing the exit shaft, you will need to hook the notched edge of the shaft into the belt before snapping the roller back into place. Notched side should be installed to the left.

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Section 3: Removing the Front Cover Removing the Front cover is necessary to access the Label Clamping Assembly and to replace the left and right ink pads. 1. Remove the Top Cover (Refer to Section 1). 2. Remove two T10 Torx screws.

3. Loosen the Phillips head screw on the bottom of the Printer.

4. Loosen the top Phillips head screw which is attached to the Front Cover from behind. Note: When replacing this screw, do not over tighten! Over tightening will result in problems replacing the Top Cover.

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5. Loosen the bottom Phillips head screw which is attached to the Front Cover from behind. Note: When replacing this screw, do not over tighten! Over tightening will result in problems replacing the Top Cover.

6. Disconnect J1 (Frnt Panel) from the main board. 7. Remove wire from wire harness. 8. Remove the Front Cover.

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Section 4: Replacing the Label Clamp Assembly • Part Number 660030

1. Remove the Front Cover (Refer to Section 3 for Instructions) 2. The label Clamp Assembly is secured by four T10 Torx screws.

3. Remove the two right side torx screws.

4. Remove the two left side torx screws.

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5. Disconnect J18 (Label Clamp Sensor) and J2 (Label Clamp Motor) from the Main Board.

6. Tip the Label Clamp Assembly forward. 7. Pull the Assembly up and out and set it on the table.

8. Remove the wires from the unit by feeding the main board connections through the hole in the metal frame.(Remove wires from wire harness)

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9. Locate the new label clamp assembly.

10. Feed the connectors through the hole in the metal frame. (Put the wires back into the wire harness) 11. Set the Assembly in place as shown.

12. Tip the Assembly up and partially into place. 13. Make sure the bottom edge is resting on the metal base of the Printer and not on an ink pad.

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14. To complete the installation, snap the metal tabs under the metal roller guide.

15. When reconnecting wires to the main board make sure J2 (Label Clamp Motor) is correctly connected. It is possible to reconnect it up side down causing the clamp to be on when it should be off. The red wire should be on the left – Black should be on the right. 16. Replace the Torx screws, the Front Cover and the Top Cover.

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Section 5: Replacing the Ink Pads • Part Number 074220 (Contains Right and Left Side Pads and Center Air Filter Pad)

A. Replacing the Center Air Filter Pad 1. Turn the printer on its side so you can access the bottom. 2. Remove two Phillips head screws as shown.

3. Slide the Air Filter Frame out of the base.

4. Remove the used filter.

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5. Place the new filter in the slot. 6. Replace the Air Filter Holder. 7. Replace the screws.

B. Replacing the left and right side pads. The left and right side ink pads come in a kit with the Center Air Filter. The pads are shown on the right. It is possible to install the left and right side pads by removing the air filter frame (Section 5A) and blindly removing them from the pins on the base of the unit. However, it may be easier to install the pads using the following procedure. To install the pads you will need to remove the Top Cover, Front Cover and the Label Clamp Assembly. Refer to sections 1, 3 and 4 respectively. It is possible to replace the pads with out removing the Label Clamp Assembly (Section 4). However, in the following photos it has been removed to allow for a better view.

1. Remove the saturated left and right side pads from the printer base. The pads are held in place by three straight pins and one pin with a washer on top. The washer pin holds the pad down so it will take slightly more effort to move the pad over this pin.

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2. Place the new pads over the pins. The pads have holes that correspond to the pins.

3. A correctly installed ink pad is shown on the right.

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Section 6: Replacing the Feed Motor • Part Number 660101

1. Remove the Top Cover as described in Section 1. 2. Locate the Feed Motor on the left side of the unit above the main board. 3. Remove Power from the main board.

4. Remove two Phillips head screws from the top left and bottom right.

5. Disconnect the belt from the pulley on the motor.

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6. Install the new motor. 7. Hook the pulley back into the belt. 8. Replace the Motor Mount Screws. 9. Loosen three Motor Bracket Mount screws ¾ turn each. Twist the motor assembly free and then allow the spring to tension the belt. Retighten screws starting with the lower right and proceeding in a clockwise direction.

10. Reattached power to the main board. 11. Replace the Top Cover.

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Section 7: Replacing the Main Board • Part Number 140400

1. Remove Top Cover (Refer to Instructions in Section 1). 2. Remove all connections from the main board. TIP: It may be helpful to label the loose connectors with the Junction letter codes. (Example - J18)

3. Remove the four T10 torx screws located at each corner of the main board.

4. Tip the board out and pull up as shown. You must clear the power switch on the left before you can completely remove the board.

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5. Locate the new main board. 6. Reattach the connections. Note: All of the wire connectors can only be correctly seated in one connection on the main board. Each connector type as a different number of pins. The 4 white connectors fit on the short pins

The 5 blue connectors fit on the long pins. One orange connection fits on the long pins.

Three connections on the main board are left empty:

• J10 • J17 • Test Port

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Section 8: Replacing the Loop Sensor • Part Number 140402,140403

1. Remove the Top Cover (See section 1 for Instructions). 2. Disconnect the Label Loop Sensor (J19) connector from the main board. 3. Disconnect the Loop LED (J20) connector from the main board.

4. Remove two phillips screws securing the loop sensor bracket as shown. 5. Remove the loop sensor bracket. (Feed the connectors through from the main board area.)

6. Remove two torx screws from both the LED(front) and the sensor (rear). 7. Locate new sensors. Replace screws and connectors. Reattach loop sensor bracket.

Front

Rear

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Section 9: Removing a Jam in the Label Sensor 1. Remove the Top Cover (Refer to Section 1 for Instructions). 2. Remove the Printer Module (Refer to Section 2 for Instructions). 3. Remove the two T10 torx screws to access the area under the label sensor.

4. Remove the top portion of the TOF sensor housing. 5. Remove the jammed label stock. 6. Clean the metal components of any label debris with Isopropyl alcohol. 7. Reinstall all parts.

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Appendix A - Parts List Part Number Description Price 074220 Kit-LX810 Ink Pad Replacement $12.32

660200 Module-LX810 Replacement Printer $310.44

660030 Assembly - Label Clamp $217.62

660101 Assembly - Feed Motor $113.04

660314 Roller-Label Feed $95.28

140400 LX810 Main Board $213.30

140403 LX810 Loop Sensor $17.93

140402 LX810 Loop LED $7.32

140392 LX810 EDGE CLAMP SNS $8.46

Boxing / Accessories

052209 CABLE-USB A-B 6' $4.50

053376 CARTRIDGE-LX/BP COLOR DYE $47.95

053377 CARTRIDGE-LX/BP BLACK DYE $42.95

053020 CARTRIDGE-LX/BP BLACK PIGMENT $42.95

130063 POWER CORD-BLACK $9.12

150404 PWR SUPPLY EXT 12V - 60W $55.50

062067 Supply Pack LX810 (Manual Etc.) $14.28

260374 BOX-LX810 OUTER $24.30

260376 END CAP SET-LX810 $42.00

510943 MANUAL LX810 $6.60

510929 QUICK START-LX810 $2.34

074890 LBL STOCK-STARTER 6"X4" $20.28 *Prices are subject to change with out notice. Please contact the Supplies Dept. for the latest pricing information 1-800-797-2772